Twin-sheet thermoforming process

ABSTRACT

A twin-sheet thermoforming process for the manufacture of vehicle headliners. In the process a first sheet and second sheet of SuperLite material are mounted onto respective frames. The frames transfer the sheets into an oven, where they are heated to a desired temperature using IR. The first sheet is combined with a cover-stock material using compression molding forming a covered first headliner part. The covered first headliner part is then transferred to a second mold station. The second sheet is heated and then transferred from the oven to the second mold station where it is vacuum-formed on the upper half mold, forming a second headliner part. The upper and lower mold halves are pressed together fusing and sealing the first and second headliner parts into a unified part. The unified part is then unloaded and trimmed as necessary forming a headliner. The SuperLite material used to form the headliner is a sheet of low pressure, thermoformable, thermoplastic composite comprised of polypropylene and long chopped glass fibers.

CROSS REFERENCE TO RELATED APPLICATION

The application claims the benefit of the priority filing date of theprovisional patent application filed Apr. 4, 2003, bearing Ser. No.60/460,556.

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for makingtwin-sheet thermoformed material and, more particularly to a process formaking twin-sheet thermoformed material for use as vehicle headliners,wherein the head liner imparts improved head impact protection and soundproofing to the vehicle.

BACKGROUND OF THE INVENTION

Traditionally, product made from a twin-sheet thermoforming process,with respect to the interior of a vehicle, has been used in applicationssuch as rear parcel shelves, door panels, pillar trim, and load-floors.Such a process has not been used for the manufacture of vehicleheadliners.

Currently, most vehicle headliners include extra Head ImpactCountermeasures (HIC), such as PU foam blocks, attached in strategicpositions on the back of a headliner substrate. These HIC parts areexpensive and necessitate a secondary operation to affix these parts.These parts are usually made from materials such as Polyurethane,Expanded Polypropylene, Polypropylene, Polyethylene, Polystyrene, andothers.

What is needed is for a twin-sheet thermoform process for themanufacture of vehicle headliners. Also needed is for the process toobviate the need for HIC parts by molding the proper geometry into theheadliner substrate itself. Moreover, it is desired that the processintroduces fabric into the vehicle headliner, thereby obviating the needfor adhesively adhering the fabric to the headliner. Further needed isfor the headliner to have beneficial acoustic properties.

SUMMARY OF INVENTION

The invention a headliner for a vehicle and a method for making thesame, wherein the headliner has improved Head Impact Countermeasures(HIC) properties, acoustic properties and cost of manufacture. Theheadliner is comprised of a first headliner part and a second headlinerpart. The first headliner part is a first sheet having a liner side andan opposing side, wherein the first sheet is molded into a shape that issubstantially the shape that is visible as seen from inside of thevehicle. The second headliner part is a second sheet having a roof sideand a compartment side, wherein the second sheet is molded to reinforcethe first headliner part, attach the headliner to the roof, form atleast one interior compartment that cushions impact when combined withthe first headliner part, and form an intra-panel space between the roofand the second first headliner part. The first headliner part and thesecond headliner part are adhered to each other forming a unified parthaving compartments. The interior compartments provide excellent headimpact countermeasures (HIC) properties, as the sheets comprisingheadliner parts have a composition with sufficient flex to give whenimpacted. The interior compartments act to cushion a blow if an incidentoccurs wherein someone impacts the headliner. The second headliner partshape furthermore creates at least another intra-panel space between thesecond headliner part and the roof. The intra-panel space produces sounddampening, particularly from noise emanating from the roof. Theintra-panel space also provides an additional region for absorbingimpact. A preferred composition for the headliner is a thermoplasticcomposite that can be vacuum thermoformed. Typically, the composition ofboth headliner parts is a low pressure, thermoformable, thermoplasticcomposite comprised of polypropylene and long chopped glass fibers. Theheadliner is preferably further comprised a cover-stock material, suchas a fabric, a film, a felt, or a skin such as a fur or a leather. It isanticipated that as other cover-stock materials can be employed.Examples of less popular potential cover-stock materials include foams,knits, carpets, rubber padding, and coatings. Depending on the method ofmanufacture and the nature of the cover stock material, the cover-stockmaterial can be adhered directly to the thermoplastic composite, oradhered with an adhesive. Normally, an intra-layer adhesive is employed,which bonds the thermoplastic composite first sheet to the cover-stockmaterial forming a covered first headliner part. The cover-stockmaterial is typically pre-coated with an adhesive using a web convertingprocess, wherein a heat activated adhesive is coated onto thecover-stock material. The thermoplastic composite is then laminated tothe cover-stock material using matched mold compression thermoforming.Alternatively, a filmic adhesive can be employed to produce the coveredfirst headliner part. The cover-stock material can also have anunderlying layer of foam, which acts principally to impart a tactilesoftness to the cover-stock material. The first headliner part canadditionally have a fusing adhesive on the opposing side of the firstheadliner part. The adhesive enhances the bond between the first andsecond headliner parts. The roof side of the second headliner part canhave a reinforcing scrim layer, such as a nonwoven or woven polyester orglass fiber forming a reinforced scrim second headliner part. The secondheadliner part can additionally have a fusing adhesive on thecompartment side of the second headliner part. The adhesive enhances thebond between the first and second headliner part. The thickness, densityand composition of the first and second headliner parts are selected toprovide impact cushioning. The thickness range is from about 2 mm toabout 10 mm. The glass content is about 35% to 65%, with a morepreferred composition of 40% to 57% by weight. The coefficient ofthermal expansion (CTE) is from about 12×10⁻⁶ mm/mm/° C. to about19×10⁻⁶ mm/mm/° C. over a temperature range of −40° C. to +70° C. Thetrend correlates that the higher the density, the higher the CTE. Priorto combining the first headliner part to the second headliner part, thevacuum formed headliner parts can be fitted with additional componentssuch as duct work, wiring, electronic devices, conduits, reinforcinglayers and fastening elements, etc. The additional components can besecured using vibration, ultrasonic and hot plate welding.

The process for forming a headliner is comprised of the steps of:placing a first sheet in a first frame, which tensions the sheet on atleast two sides and preferably four, and transferring the first sheetinto an oven; heating the first sheet in the oven to a predeterminedtemperature; transferring and vacuum molding the first sheet onto a halfmold of a thermoforming mold forming a vacuum molded first headlinerpart; placing a second sheet in a second frame and transferring thesecond sheet into the oven or, if available, an alternate oven; heatingthe second sheet in the oven to a predetermined temperature;transferring and vacuum molding the second sheet onto an opposing halfmold of the thermoforming mold forming a vacuum molded second headlinerpart; compressing the half molds of the thermoforming mold fusing thevacuum molded first headliner part to the vacuum molded second headlinerpart, thereby forming a unified part having at least one interiorcompartment having impact cushioning; ejecting the unified part; andtrimming and finishing the unified part. The first and second sheets arepositioned in the thermoforming press such that, for sheets having afusing adhesive, the fusing adhesives are face-to-face, and the fusingadhesive is not in contact with either the half mold. The processreduces the number of steps from forming two traditionally compressionmolded sheets and then uniting these sheets to a single two step vacuummolding process, which produces the sheets and then in the same moldcombining the sheets into a unified part. The process can be amended tofurther comprise thermoforming the first sheet to have cover-stockmaterial forming a compression molded covered first headliner part.After heating the first sheet in the oven to the predeterminedtemperature, the first sheet is transferred to a thermoforming moldhaving matched mold halves, and a cover-stock material is transferred tothe thermoforming mold and the mold is compressed thereby fusing thecover-stock material to the first sheet forming a compression moldedcovered first headliner part. The process enables inline preparation ofthe headliner with a desired cover-stock, thereby forming a coveredunified part. The cover-stock material can comprise an underlying layerof foam and an intra-layer adhesive. The process can additionallyinclude adding a reinforcing scrim to the second sheet using compressionmolding therein forming a compression molded reinforced scrim secondheadliner part. After heating the second sheet in the oven to thepredetermined temperature, transferring the heated second sheet to athermoforming mold having matched mold halves, there is transferred areinforcing scrim material to the thermoforming mold having matched moldhalves. The mold is closed compressing and fusing the reinforcing scrimmaterial to the second sheet forming a compression molded scrimreinforced second headliner part. The compression molded scrimreinforced second headliner part is then transferred onto the opposinghalf mold of the thermoforming mold. The thermoforming mold compressesthe half molds, which adheres the layer of fusing adhesive on thecompression molded covered first headliner part to the layer of fusingadhesive on the compression molded reinforced scrim second headlinerpart, thereby forming a covered reinforced scrim unified part. Thecovered reinforced scrim unified part is a headliner having high impactcushioning and an esthetically appealing cover-stock.

In subsequent trimming and finishing steps the unified part has theselvage removed, and the interior compartments can be modified byinjecting foam and insulation into the compartment.

OBJECTS OF THE INVENTION

The principal object of the present invention is to provide a twin-sheetthermoform process that produces a unified part, and in particular avehicle headliner.

A second object of the invention is to provide a process for forming aheadliner having impact cushioning.

A third object of the invention is to provide a twin-sheet thermoformprocess that includes the introduction of a fabric into a formed vehicleheadliner.

A fourth object of the invention is to provide a process for forming aheadliner having sound dampen qualities.

A fifth object of the invention is to provide a twin-sheet thermoformprocess that obviates the need for PU foam blocks in a vehicleheadliner.

A sixth object of the invention is to provide a hollow vehicle headlinerusing low-density glass-filled materials with a thermoplastic resinmatrix.

A seventh object to of the invention is to provide a twin-sheetthermoform process that lends itself to integrating components such asduct work, wiring, electronic devices, conduits, reinforcing layers andfastening elements, etc. into the headliner. The additional componentscan be secured using vibration, ultrasonic and hot plate welding orconventional fastening means.

A final object of the invention is to provide a twin-sheet thermoformprocess which reduces the cost associated with vehicle headliners formedby traditional processes.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects will become more readily apparent byreferring to the following detailed description and the appendeddrawings.

FIG. 1 is a schematic drawing illustrating the process of forming aheadliner using a single mold to vacuum form a first and second sheet ofa thermoplastic composite, and then to unify the two molded sheets.

FIG. 2 is a cross sectional view of a first headliner part 18 having acover-stock 34 and a second headliner part backed with a reinforcingscrim 42.

FIG. 3 is a cross-sectional view of a unified part, a headliner 30, asshown relative to the roof of a vehicle.

FIG. 4 is a two-stage oven inline process schematic for making aheadliner having a cover-stock material.

FIG. 5 is a double oven double thermoforming molding inline processschematic for making a headliner having a cover-stock material.

FIG. 6 is a two-stage oven rotary process schematic for making aheadliner having a cover-stock material.

DETAILED DESCRIPTION

As described herein and illustrated by the drawings, the presentinvention is a two-sheet thermoform process for producing a thermoformedproduct. In particular, the invented process is particularly useful inproducing vehicle headliners. Further, the process allows for aheadliner to be formed with a fabric and formed into a desired shape. Assuch, this process resolves concerns such as adhesion of fabric to theheadliner, while preserving acoustic properties.

In general the invented two sheet process includes the steps of placinga first sheet of material, such as SuperLite, into a frame, then heatingthe material in a preheat oven. SuperLite® is a product of Azdel, Inc.SuperLite is thermoplastic composite that can be vacuum thermoformed.The composition of both sheets is a low pressure, thermoformable,thermoplastic composite comprised of polypropylene and long choppedglass fibers. The sheets have a flexural modulus between 900 and 1800MPa (ASTM D792), and a multi-axial impact between 5 and 7 J (ASTMD3763). The thickness of the sheets is 2 to 5 mm, with 2.5 to 3.5 mmbeing more preferable. The headliner is preferably further comprised acover-stock material, such as a fabric, a film, a felt, or a leather.The molded sheets are headliner parts that are assembled so as to forminterior compartments, which provide cushioning against impact. Whenmounted to the roof of the vehicle, there is an intra panel spacebetween the roof and the headliner. The intra panel space providesadditional other impact cushioning, as the headliner is composed ofmaterials that are designed to flex, therein providing extra Head ImpactCountermeasures (HIC). The compartments and the intra-panel space alsoprovide sound isolation, particularly from noise emanating from theroof.

Referring now to the figures, FIG. 1 is a schematic drawing illustratingthe process for forming the headliner using a single thermoforming mold10 to vacuum form a first and second sheet of a thermoplastic composite,and then to unify the two molded sheets. A first sheet 18 is placed in aframe 26 and then moved into an oven 16. The oven is either an IR, airimpingement, hot air, RF or a combination thereof. The IR ovens offerthe advantage of requiring little floor space, no ventilation, andprofiling the heat intensity. Generally electric IR is preferred to gasIR as no exhaust gas ventilation is required. A medium wavelengthinfra-red (2–4 microns) is commonly employed. Heating time is about40–60 seconds, which is sufficient to warm the sheet to about 180° C. to225° C. The sheet material employed in a typical headliner is 2.5 mmthick, and has a weight from about 750 to about 950 GSM. When the firstsheet reaches the desired temperature it is transferred into the mold asshown in Step 2 of FIG. 1 where it is vacuum formed on the lower halfmold 12 forming a first headliner part, and the second sheet, loaded ona second frame 26, is transferred into the oven 16. In Step 3, theheated second sheet 20 is transfer into the mold 10, where it is vacuumformed on the upper half mold 14, forming a first headliner part. InStep 4, the mold 10 is closed in the compression mode. The upper andlower half molds have matching surfaces, which regionally cause thefirst and the second headliner parts to be compressed against eachother, therein fusing regions of the two headliner parts forming aunified part 22. The unified part has at least one interior compartment28, which provides impact cushioning. In Step 5, the mold is opened andthe unified part 22 is ejected, and transferred to the trimming andfinishing station. In Step 6, the selvage is removed and finishing stepsare completed, such as welding, attachment of fastening elements, ormodification of the interior compartment is completed. For instance amodification of the compartment would be to fill it with foam.

Referring to FIG. 2, which is a cross sectional view of the firstheadliner part 19 having a cover-stock 34 and the second sheet backedwith a reinforcing scrim 42. From the top down, the first headliner part19 has a cover-stock materials 34, an intra-layer adhesive 34, a lowpressure thermoformable, thermoplastic composite comprised ofpolypropylene and long chopped glass fibers 38, and a fusing adhesive40. The second headliner part 21, has a fusing adhesive 40, a lowpressure thermoformable, thermoplastic composite comprised ofpolypropylene and long chopped glass fibers 38, and a polyester scrim42. The sheets have a flexural modulus between 900 and 1800 MPa (ASTMD792), and a multi-axial impact between 5 and 7 J (ASTM D3763). Thethickness of the sheets is 2 to 5 mm, with 2.5 to 3.5 mm being morepreferable. The cover-stock material is a fabric, a film, a felt, or aleather 38.

FIG. 3 is a cross-sectional view of the headliner 30, as shown relativeto the roof 44 of a vehicle. The first and second headliner parts areadhered at four points, each numbered 32. There are three interiorcompartments, each numbered 28. There is an intra panel space 58 createdbetween the roof 44 and the headliner 30. The interior compartments 28provide impact cushioning. The intra panel space 58 provides noisesuppression. The cover-stock material 34 on the first headliner part 19faces the interior of the vehicle. The cover-stock material canadditionally have an underlying layer of foam to improve the tactilefeel of the cover-stock material.

The lamination of the cover stock material to the first sheet can beincorporated into the manufacture of the headliner. FIG. 4 a two-stageoven inline process schematic for making a headliner having acover-stock material. In the process the first sheet 18 is fed by anautomatic loader 50 into a two-stage oven, where the first stage is apreheater 46 and the second stage is higher temperature oven 16. Theovens act also as a holding station for the sheets to be warmed whilethey are being prepared for molding. A frame transfers the first sheetto the preheater 46 and then to the oven 16, where it is warmed to thetemperature needed for molding. Upon reaching the desired temperaturethe warmed first sheet 18 and the cover-stock material 26 on a frame 56are transferred into a thermoforming mold 10, where the mold 10 isfitted with matched mold halves. The cover-stock is compression moldedto the first sheet forming a compression molded covered first headlinerpart. The compression molded covered first headliner part is ejected,and the process is repeated until a sufficient quantity of covered firstheadliner parts have been produced. Similarly, the second sheet can becompression molded forming a compression molded reinforcing scrim secondpart using the cover stock frame 56. The matched halves are removed, andthe mold 10 is set up for vacuum molding. The compression molded coveredfirst headliner parts are then processed back through the line usingvacuum forming, as required. From the auto-loader 50, the compressionmolded covered first headliner part and then the second sheet are fedinto the preheater 46 and then the oven 16. The compression moldedcovered first headliner part 19 is positioned on the lower half mold 12,and the second sheet 20 is vacuum formed on the upper half mold 14forming the vacuum molded second headliner part 21, respectively. Theheadliner parts are then compression molded, wherein matching surfacesregionally cause the first and the second headliner parts to becompressed against each other, fusing and sealing the regions ofcompression. The compression unifies the two into a single coveredunified part 22. The covered unified unified part 22 is ejected to theunload station and transferred to the trim station 54, where selvage andother finishing operations are performed. In a variation in processusing the same equipment, after the first sheet is compression moldedwith the cover sheet forming the compression molded covered headlinerfirst part, the top matched half mold can be removed, and the secondsheet can be vacuum molded in the top half mold 14 forming vacuum moldedforming a vacuum molded headliner second part. The two sheets can thenbe fused and sealed using compression molding. The addition of thecover-stock material is optional, and the process can be employed usingsheets that either do not have a cover-stock material, or arepre-laminated with the liner cover stock. Of course, this also true forthe reinforcing scrim.

FIG. 5 depicts a double oven double thermoforming molding inline processschematic for a headliner having a cover-stock material. In the thisprocess the first mold 48 is fitted with matched halves and is operatedto compression mold the cover-stock 34 to the first sheet 18. Thecovered first sheet is then transferred to the second mold 10, where itis positioned in the lower half mold 12. The second sheet 20 is vacuummolded to the top half mold 20, and the two sheets are compressionmolded into the unified part 22. The unified part 22 is ejected to thetrim station 54, where the selvage is removed and finishing is completedforming a headliner 30. The inline process is particularly productive asit has two molds, 48 and 10, and two auto-loaders, 50 and 51.

FIG. 6 is a two-stage oven rotary process schematic for making aheadliner having a cover-stock material. The rotary process isessentially the same as described for the inline process depicted inFIG. 5.

The drawings illustrate alternative thermoform process configurationsfor accomplishing the manufacture of twin-sheet thermoform headliner.For example, the process steps may be set-up in a linear or rotaryarrangement.

SUMMARY OF THE ACHIEVEMENT OF THE OBJECTS OF THE INVENTION

From the foregoing, it is readily apparent that we have invented animproved process for the manufacture of thermoformed material and, inparticular, for the manufacture of vehicle headliners. It is alsoapparent that we have invented an improved vehicle headliner that isformed by the invented process. The headliner has improved impactcushioning, improved acoustic qualities, lower cost. The process enablesquick changeovers from one headline cover-stock material to another, andprovides a mechanism of integrating components such as duct work,wiring, electronic devices, conduits, reinforcing layers and fasteningelements, etc. into the headliner.

It is to be understood that the foregoing description and specificembodiments are merely illustrative of the best mode of the inventionand the principles thereof, and that various modifications and additionsmay be made to the apparatus by those skilled in the art, withoutdeparting from the spirit and scope of this invention.

1. A thermoform process comprising the steps of: placing a first sheetin a first frame and transferring the first sheet into an oven, whereinsaid first sheet is a low pressure, thermoformable, thermoplasticcomposite comprised of polypropylene and long chopped glass fibers;heating the first sheet in the oven to a temperature; placing a secondsheet in a second frame and transferring the second sheet into the ovenor an alternate oven, wherein said second sheet is a low pressure,thermoformable, thermoplastic composite comprised of polypropylene andlong chopped glass fibers; heating the second sheet in the oven to atemperature; transferring the heated first sheet to a thermoforming moldhaving matched mold halves; transferring a cover-stock material to thethermoforming mold having matched mold halves; compressing and fusingthe cover-stock material to the first sheet forming a compression moldedcovered first headliner part; repeating the process until a sufficientnumber of compression molded covered first headliner parts are formed;removing the matched mold halves and setting up the mold for vacuumthermoforming with a lower half mold and an opposing half mold;transferring the compression molded covered first headliner part to thelower half mold of a vacuum thermoforming mold; transferring the secondsheet onto the opposing half mold of the vacuum thermoforming mold;vacuum molding the second sheet forming a vacuum molded second headlinerpart; positioning wiring, duct work or reinforcing components into whatwill become the interior compartment; compressing the half molds of thethermoforming mold fusing regions of the compression molded coveredfirst headliner part to the vacuum molded second headliner part, therebyforming a covered unified part comprised of said compression moldedcovered first headliner part and said vacuum molded second headlinerpart, where said covered unified part has at least one interiorcompartment with head impact cushioning; and ejecting the coveredunified part.
 2. The thermoform process as claim 1, wherein said firstsheet is a low pressure, thermoformable, thermoplastic composite thathas a flexural modulus of about 900 MPa to about 1800 MPa as determinedby ASTM D792.
 3. The thermoform process as claim 1, wherein said secondsheet is a low pressure, thermoformable, thermoplastic composite thathas a flexural modulus of about 900 MPa to about 1800 MPa as determinedby ASTM D792.
 4. The thermoform process as claimed in claim 1, whereinthe vacuum molded second headliner part is further comprised of a layerof a fusing adhesive.
 5. The thermoform process as claimed in claim 1,wherein the cover stock material is comprised of a fabric, a film, or afelt, or a far, or a leather.
 6. The thermoform process according toclaim 1, wherein the cover stock material is farther comprised of anunderlying layer of foam.
 7. The thermoform process according to claim1, wherein the cover stock material is further comprised of anintra-layer adhesive.
 8. The thermoform process as claimed in claim 4,wherein compressing the half molds of the thermoforming mold fuses thelayer of adhesive on the vacuum molded second headliner part to thecompression molded covered first headliner part, thereby forming anadhesively laminated covered unified part.
 9. The thermoform process asclaimed in claim 1, wherein the covered unified part is a headliner. 10.A thermoform process according to claim 1, further comprising the stepof: after compressing the half molds of the thermoforming mold fusingthe compression molded covered first headliner part to the vacuum moldedsecond headliner part Thereby forming the covered unified part;injecting foam into the interior compartment.
 11. A thermoform processaccording to claim 1, further comprising the step of: after compressingthe half molds of the thermoforming mold fusing the compression moldedcovered first headliner part to the vacuum molded second headliner partthereby forming the covered unified part; injecting insulation into theinterior compartment.
 12. A thermoform process according to claim 1, isfurther comprised of the step of: trimming and finishing the coveredunified part, where finishing is selected from the processes consistingof: secondary punching, laser, knife trimming, and vibration, ultrasonicand hot plate welding.
 13. A thermoform process according to claim 1,further comprising the step of: after placing a first sheet in the firstframe, transferring the first sheet into a preheat oven; preheating thefirst sheet to a temperature.
 14. A thermoform process according toclaim 13, further comprising the step of: after placing a second sheetin the second frame, transferring the first sheet into a preheat oven;preheating the second sheet to a temperature.
 15. A thermoform processcomprising the steps of: placing a first sheet in a first frame andtransferring the first sheet into an oven; heating the first sheet inthe oven to a temperature; placing a second sheet in a second frame andtransferring the second sheet into the oven or an alternate oven;heating the second sheet in the oven to a temperature; transferring theheated first sheet to a thermoforming mold having matched mold halves;transferring a cover-stock material to the thermoforming mold havingmatched mold halves; compressing and fusing the cover stock material tothe first sheet forming a compression molded covered first headlinerpart; transferring the heated second sheet to a thermoforming moldhaving matched mold halves; transferring a reinforcing scrim material tothe thermoforming mold having matched mold halves; compressing andfusing the reinforcing scrim material to the second sheet forming acompression molded scrim reinforced second headliner part; repeating theprocess until a sufficient number of compression molded covered firstheadliner parts and compression molded scrim reinforced second headlinerparts are formed; removing the matched mold halves and setting up themold for vacuum thermoforming with a lower half mold and an opposinghalf mold; transferring the compression molded covered first headlinerpart to the lower half mold of a vacuum thermoforming mold; transferringand positioning the compression molded scrim reinforced second headlinerpart onto the opposing half mold of the vacuum thermoforming mold;vacuum molding the scrim reinforced second headliner part to form avacuum molded scrim reinforced second headliner part; positioningwiring, duct work or reinforcing components into what will become theinterior compartment; compressing the half molds of the thermoformingmold fusing regions of the compression molded covered first headlinerpart to the vacuum molded scrim reinforced second headliner part,thereby forming a reinforced covered unified part comprised of saidcompression molded covered first headliner part and said vacuum moldedscrim reinforce second headliner part, where said reinforced coveredunified part ha at least one interior compartment with head impactcushioning; and ejecting the reinforced covered unified part.
 16. Thethermoform process according to claim 15, wherein the cover stockmaterial of the compression molded covered first headliner part isfurther comprised of an underlying layer of foam.
 17. The thermoformprocess according to claim 16, wherein the cover stock material of thecompression molded covered first headliner part is further comprised ofan intra-layer adhesive.
 18. A thermoform process according to 15,further comprising the step of: After compressing the half molds of thethermoforming mold fusing the compression molded covered first headlinerpart to the vacuum molded scrim reinforced second headliner part therebyforming the reinforced covered unified part; injecting insulation intothe interior compartment.